Method for production of brush construction



Feb.- 8, 1966 G. SHAW 3,233,944

METHOD FOR PRODUCTION OF BRUSH CONSTRUCTION Original Filed Aug. 15, 1962 8 Sheets-Sheet 1 7 mmvrm ATTO RNEYS Feb. 8, 1966 G. SHAW 3,233,944

METHOD FOR PRODUCTION OF BRUSH CONSTRUCTION Original Filed Aug. 15, 1962 8 Sheets-Sheet 2 F'IG-8.

mrumrsn me: or FIG. 6.

\q 0 i 1000 S k v;

INST/1N6! FROM NON-JWEZPING {N0 DIRECT/0N 0F SWEEP/N6 END' F'IG.9.

JPATULATED FIBRE 0F FIG. 6.

THICKNESS IN [MCI/[S D7! TANCE FROM NON-J'WH'P/NG END --'DIRCTION 0F SHEEP/NC END INVENTOR. GI LBERT SHAW BY I 777m Y ATTORNEYS Feb. 8, 1966 SHAW 3,233,944

METHOD FOR PRODUCTION OF BRUSH CONSTRUCTION Original Filed Aug. 15, 1962 8 Sheets-Sheet 5 F I (3. IO.

.SPATULATED FIBRE of F l cs. 7 4.00

v; v; w a 1.00 a u. I I

our/we! FROM NON-SWEEP/NC END D/REC7'10N 0; SWEEP/NC /v0 F l G- l l- SPATULATED FIBRE 01- F IG. 7. 3 0.0200

u; 4 1 i 2 0.0100 E 00050 DISTANCE FROM NDN-JWEfP/NC E/VD DIRELTION 0F SWEEP/NC END INVENTOR. GILBERT SHAW ATTORN EYS Feb. 8, 1966 G. SHAW 3,233,944

METHOD FOR PRODUCTION OF BRUSH CONSTRUCTION Original Filed Aug. 15, 1962 8 Sheets-Sheet 4 F I (3. l2.

5.75 TYPICAL cox/v snoom FIBRE g 4.00 {3 3.00 k "a 2.00

01. max

0/5 rmvcz FROM NON-.$WEP/NC END 0/RcT/o/v 0F SWEEP/N0 ND' F l (3. l3.

0 0040 TYPICAL comv BROOM FIBRE 0.036 0.030 0-030 3 0.020 35 0.0/0 t, 0.010 g 0% 25% 50% 157- 3 mam/v0: FROM NOIV- SWEEP/N6 END INVENTOR. GILBERT SHAW ATTORN EYS Feb. 8, 1966 a W 3,233,944

METHOD FOR PRODUCTION OF BRUSH CONSTRUCTION Original Filed Aug. 15, 1962 8 Sheets-Sheet 5 FIG-I4- FIG.I5. FIG-I6.

PRIOR ART .F' l (3. l9.

INVENTOR. GI LBERT SHAW ATTORNEYS Feb. 8, 1966 G. sHAw 3,233,944

METHOD FOR PRODUCTION OF BRUSH CONSTRUCTION Original Filed Aug. 15, 1962 8 Sheets-Sheet 6 INVENTOR.

GILBERT SHAW 43 \\\\\\\\llIIIHIHI/l/lfl/ j 9 BY ATTORN EYS 1966 G. SHAW 3,233,944

METHOD FOR PRODUCTION OF BRUSH CONSTRUCTION Original Filed Aug. 15, 1962 8 Sheets-Sheet 7 TF'IG- 26 fig F I 3 27 26A 26B 26C IN iii gpfi ffr 132 255 first: 3 3 F|G-26A I Q ZES Q W :1 SECTION c-c m Flcs 2eg fld F' l G- 39 M2 w a' 265 m5 (9/ A A (g v 100 INVENTOR. G l LBERT SHAW 71%; W, MW?! ATT RNEYS Feb. 8, 1966 sH w 3,233,944

Original Filed Aug. 15, 1962 8 Sheets-Sheet 8 F l G. 28A. F l G. 285.

INVENTOR. G l LEE RT SHAW fig M Mun w ATTO R N EYS as brush fibers.

United States Patent 11 Claims. (Cl. 300-41) This invention relates to improved methods for the manufacture of a brush construction.

This application is a division of my co-pending application, Serial No. 217,000, filed August 15, 1962.

During the last twenty-five years, synthetic fibers, mainly in oriented filament form, have found increasing usage Their acceptance has been brought about as a result of decreasing supplies of natural brush filling materials, the greater demand for natural brush filling materials caused by overall world population growth and greater purchasing power, and the rising trend of natural brush fiber prices that parallels world prices in general.

Although various efforts have been made to modifythe shape and composition of synthetic brush fibers to permit closer approximation of the action of natural brush filling materials, synthetic materials have in many instances fallen short of the performance of natural materials. Brush manufacturing methods, highly developed for handling natural materials, have remained essentially unchanged in the face of replacement of natural materials by synthetics and have never fully utilized the basic physical properties of synthetic brush filling materials.

The need for improved synthetic brush fibers and brush constructions can be illustrated by describing the major desirable properties of natural fibers, and by reviewing theetforts that have been made to make synthetic fibers more acceptable in the past.

Hog bristles are admirably suited for use in paint brushes and other'uses. They possess a diameter reduction in the direction of the working or painting end. The attendant decreasein stiffness in the direction of the working end is highly desirable because of the flexing hand imparted to a brush. At the working end of each hog bristle, the bristle splits into a multiplicity offinerfilaments which is customarily called the flower or flag. 'The flag facilitates smooth application of paint or liquids. As the bristles wears dowrnthe flag continues to split off the main bristle stem so that excellent performance from a painting standpoint continues asthe bristle wears. Follicles are present along the length of the bristle stem which add to the paint holding capacity of a hog bristle brush because of capillary action.

'Syntheticpaint brush fibers have'been manufactured with decreasing diameter in the direction of the working or painting end. Machines have been devised to mechanically split or flag the working ends of these fibers. Brushes made using such diametrically tapered and flagged fibers are widely used but they are not completely satisfactory because the smooth tapered stem makes them less effective as a paint holding medium than hog bristle. Also, becausethe mechanical force applied inpainting is barely sufiicient to continue splitting the tapered synthetic fiber, there is a tendency for the flag to wear and leave a small circular tip that is a poor paint applicator.

Paint brushes having X cross section fibers rather than solid circular have been devised. These have excellent capillarity and continue to flag in service but as yet, they have not been supplied with decreasing stifiness in the direction of the working ends.

In the instance of brooms which are madeusing broom corn, the desirable features of broom corn are similar in many respects -;to those present in hog bristles. The

individual corn fibers have a decreasing diameter in the direction of the working or sweeping end. Each fiber has a flower or flag at its sweeping end consisting of about 1 to 8 projections considerably finer than the main tapered stem. The admirable sweeping properties of broom corn are attributable to the flexing action imparted by the decreasing diameters in the direction of the sweeping ends of the individual fibers and by the multiplicity of fine sweeping ends present at the working end of acompleted broom.

Less work has been conducted in the direction of developing an adequate synthetic replacement for corn broom because that material is still readily available at reasonably low cost. Standard, uniform solid filaments of circular shape have been used to a considerable extent in so-called linoleum brooms that are used as a substitute for corn brooms. In some instances, filaments have been used which have been manufactured using filaments whose diameter, in the direction of the working end; be such that it may be readily flagged; be of such shape that the ,mechanical forces to which it is subjected during sweeping service cause flagging to continue as the fiber wears; have maximum tip surface exposed to the direction of the sweeping or paint application; and, when capillarity is required, have grooves the length of the filament to assist in liquid retention.

Objects and advantages of the invention will be set forth in part hereinafter and in part will be obvious herefrom, or may be learned by practice with the invention, the

same being realized and attained by means of the steps,

methods, combinations and improvements pointed out in the appended claims.

The invention consists in the novel steps, methods, combinations and improvements herein shown and described.

The objects of this invention will now be described. While this invention is primarily concerned with the production of brushes comprising a family of compressible, synthetic fibers which are increasingly flattened in a controlled, continuous manner along at least partof their length so that the flattened portions of the family of filaments has an increasing'reduction in thickness; it should be realized that the principles of this invention are applicable to situations wherein: (1) the family of compressible, synthetic fibers are flattened in a controlled, intermittent or discontinuous manner along at least part of their length and/or (2) the family of compressible, synthetic fibers are controllably flattened along at leastpart of their lengthsothat the flattened portion of the family of filaments does not necessarily have'an increasing reduction in thickness. In the discussion which follows, for convenience sake, the term spatulating is usedherein to designate the flattening of a family of compressible synthetic filaments along their length in a controlled manconstruction. A still further object of this invention-is to provide amethod for the manufacture of a brush of V the type set forth'in the foregoing" object wherein the their length to provide s patulations; said fibers being sup-. ported at one commonend to provide" the desiredbrush spatulau'ons are heat set. Anotherobject 'of this inven:

tion is-to provide a method for themanufacture of a brush comprising synthetic brush fibers which are compressible and which can be controllably spatulated to provide spatulations which give a greater projected working surface for a given stiffness in the direction of application than any of the presently known synthetic brush fibers. A further; object of this invention is toprovide a method for the manufacture of a brush of the type set forth in the foregoing object wherein the spatulations are heat-set.- A

still furtherobject of this invention is to provide a method for the. manufacture of a brush construction comprising a family of synthetic fibers which are increasingly spatuobject is to provide 'a method for the manufacture of a brush construction of the type .mentionedin the foregoalong at least partof their length. 7

Another, object of this invention is to provide a method ing object wherein the family 'offilaments are spatulated for the manufacture of. an vimproved"brush construction "comprising a brush fibensupport including an'inte'gral handlegand' a family of synthetic. brush fibers supported thereby; saidsupport comprising fiber ends. fused to a lated in the direction of one'common end, the fibers at the other common end being supported in such a manner to I maintain general parallel alignment of the spatulations at right angles to the direction of sweeping or application.

Yet still a further object ofthis invention is to provide a method for the manufacture of a brush construction comprising a family of synthetic fibers of-the type set forth in the foregoing object wherein thespatulations are heat set.

anceywith this invention; FIG. 1a

,solid ,mass to which said' family of fibers is fused. .A

further object is to provide ,a method=for= the manufac-.

ture of a brush construction of the type mentioned inthe foregoing object wherein the family of filamentsare spatulated along at least part of their length.

Further objects of theinvention-are to provide novel. l

methods for the; production ofs'patulated' fibers, and brush constructions employingsame, of the the foregoing objects.

In the. drawings:

FIG. 1 is a longitudinal sectional view of a hollow cylindricalfilament:which may be; spatulated in accordview. alongithe line lee-1a, ofFIG. 1.

I- IG' 2 "is a longitudinal sectional view, of a hollowlstriated filamentlwhich may be-spatulated in accordance type. set forth in is a cross-sectional with this invention. FIG'. 2aj is. across-sectional view Another. object of this invention is to provide. a method,

for the *-manufacture of a spatulated brush construction having a plurality of synthetic brush fibers which are-in: creasingly spatulated in .the direction of their working ends, the fibers being held in the brush block in such a manner that the spatulationsare in' general parallel'aligm ment at right anglesto thehdirect ion .of sweeping or application. Yet a further :j-object of this invention is to provide a method for the manufacture of a1brush constructionof the type set forth inthe foregoing object wherein the spatula'tions are heat set;

along the line 2d.2kz of=FIG. 2.

FIG. 3 is a :l0ngit udinal lsectionalview of a hollow square filament which 'may. be spatulated in accordance with this invention. FIG; 3a is; a cross-sectional view along the line 3a 3aof FIG. 3.

FIG. 4 isa perspective view of a hollow filai'menthaving longitudinal grooves which 'rnay 'Lbe, spatulated in 1 accordance with this invention. 1 FIG. 4a-is an end view of the filament of :FIGQ4. l

FIGJS is a perspective vviewofan X'-shaped filament which maybe: spatulated inaccordance with this inven- -tion. FIG. Sa is an end view of the, filament 'of FIG. 5..

A still-further object of this invention is to provide as A stillfurther object of this invention is to provide a.

method for the manufacture of a brush construction comprising a family of spatulated fibers wherein the fibers adjoining one common end are increasingly spatulatedin the direction of said common end, anda second part adjoining the other'common end is spatulated in a direction' 90 from'the spatulatingdirection of the first mendomed-spatulated part, the second mentionedspatulated part being supported in such a manner-to maintain the- 90 relationship of the spatulating directions of the firstmentioned and second-mentioned spatulated "parts. Yet

a further object of this invention is to provide a method V for the. manufacture of a brush construction of the type V i mentioned in the foregoing object whereinat least one of thespatulated parts is heat set.

prising a brush fiber support and a family of spatulated synthetic brush fibers supported thereby, said fibers being spatulated at the comon support end, said supportcomprising spatulated fiber ends-fused to a solid mass'to V which said family of spatulated fibers is fused.

Another object of this invention is to provide a method for the manufacture of an improved brush construction comprising a brush fiber support and a family of synthetic brush fibers supported thereby; said support com-. prising fiber ends fusedto a solid mass to whichisaidv family of fibers is fused, and said fused support having means for attaching a brush handle thereto. A further Another object of the invention is to provide a method for themanufacture of a shaped brush construction corn- FIG. :16.-

FIG.'6 is a plan view of the hollow filament of FIG. 1

afterityhas, beenspatulated. FIG. 6a is alongitudir'ial";

sectional viewalong the lines 6a'-'.-6a ofFIG; 6;: FIGS.

6b,6c and 6d are-cross-sectional viewsralong thetlines B-B, C .C and DI'D respectively, of FIG. 6a.

FIG. 7, i's a'front. elevational .view of the X-"shaped -filarnentiof FIG. 5 after it has ,beenspatulated; FIGS. 37a,

7b and 7c, respectively, are cross-sectional ,views along the lines, AA, B.B iand CC, respectively of 'FIG. 7. Q

FIGS, 8 and9 are graphs illustrating the decreases in stiffness and'thickn'ess along the length of the spatulated hollow fiber ofFIGJG as the cross-section of the :filament goes from circular at=6b to spatulate'at 6d; 7,

FIGS; 10 and 11 are .graphsillustratingthe decreases i in stiifness andthickness along the lengthxof the X-shaped spatulatedfibenofFIG. 7 as the crossasection goesfrom.

theX-shape at17a to the spatulate at:-7c.'

, FIGS.- 12 andr13' illustrate the :diameter and ,stiifness, correlations of'corn broom fiber.- j

FIG. 14 is a diagrammatic view-of a spatulatedfiber; of this inventionwhich illustrates how the working spatuinFIGf. 151 which has a reduced-diameter in the direction of the working end.

lated. endcovers almuchQlajrger sweeping area than would the small ;tip of a conventional filament ofthe type shown g -FIG. 16 is a front elevation View of a mold useful in I "spatulating the filaments of San already formedbrush.

along the lines 17-17 of 1 1G517 is'a sectional View FIG..18'is a perspective viewillustrating how the mold j of-FIGS. 16 and 17 may be used to spatulate a pre-de-...

termined quantity of individual fibers capable of spatu T lation which are not-connected-to abrushblock, FIG. 19

is a diagrammatic view ofa brush-like product spatulated T in the manner illustrated in FIG; I 18 with the ends heat welded or cemented together.

FIG. 20 is a frontelevation view of a broom construcprotruding I .family of fibers of the brush construction.

tion employing filaments spatulated in accordance with this invention.

FIG. 21 is a perspective view of a'mold base construction used in spatulating a family of filaments at a plurality of parts along their length.

FIG. 22 is a perspective view of one of two complementary side plates used 'in conjunction with the mold base construction of FIG. 21.

FIG. 23 is a sectional view taken along the line 23-23 of FIG. 21 with the complementary side plates in position.

FIG. 24 is a sectional view taken along the line 24-24 of FIG. 21.

FIG. 25 is a fragmentary front view of protruding spatulated fibers after removal of the bottom plates of the mold construction shown in'FIG. 24.

FIG. 26 is a front elevational view of a fiber produced in accordance with this invention having double spatulation. FIGS. 26a to 260, respectively, are cross-sectional views taken along the lines A-A, B--B and C-C, respectively, of FIG.'26 of perfectly spatulated fibers.

FIG. 27 illustrates an analysis of actual configurations for the sections locations A-A, B--B and C-C of FIG. 26 based upon a brush double spatulated in the mold of FIGS. 21 to 24.

FIGS. 28 and 28a illustrate diagrammatically the formation of a brush construction wherein the brush block and integral handle are formed from melted non-working ends of brush fibers fused to a solid mass welded to the FIG. 28b shows the brush construction resulting from the process illustrated in FIG. 28 and 28a.

FIG. 29 illustrates diagrammatically the formation of a brush construction wherein a brush block having means for attachment of a handle is formed from melted nonworking ends of brush fibers fused to a solid mass welded to the family of fibers of the brush construction.

FIG. 30 is a front elevational view of a handle adapted to be screwed into the threaded portion of the brush construction of FIG. 29 to form a brush and handle combination shown as a front elevational view in FIG. 31.

FIG. 32 is a front elevational view of a brush construction formed in accordance with the present invention wherein the brush block is provided with a tapered'hole adapted to receive a-complementary projection on the handle shown as a front elevational view in FIG. 33.

FIG. 34 is a diagrammatic view of a mold arrangement used in the formation of a brush having a tent-like construction.

FIG. 35 is a diagrammatic View of the brush construc- 'tion formed by using the mold arrangement of FIG. 34.

FIG. 36 is a diagrammatic view of a mold arrangement used in the formation of a brush construction having parallel rows of fibers. The brush construction is shown diagrammatically in FIG. 37.

FIG. 38 is a diagrammatic view of a brush formed in accordance with this invention wherein there is provided a brush block with attaching device of extremely thin plastic.

FIG. 39 illustrates diagrammatically the spatulation of a plurality of a band of solid filaments.

It has been found that synthetic fibers having ideal brush fiber characteristics may be produced by providing a family of synthetic fibers which are increasingly spatulated in the direction'of one common end, the fibers at the other common end being supported in such a manner to maintain general parallel alignment of the fiber spatulations. For brush construction, the major dimension of the flattened or spatulated tips at the working end of the fibers should face the desired direction of sweeping or application. In spatulating synthetic fibers in accordance with this invention, the fibers must be of such nature that they are compressible and capable of being permanetly deformed when pressure is applied thereto at a temperature below their melting point. In general, synthetic 6 fibers spatulated in accordance with this invention are thermoplastic filaments of the type normally used as brush fibers such, for example, as vinyl chloride polymer and ccpolymer filaments, nylon filaments, etc.

Since many thermoplastic polymers have plastic mem cries and tend to return to their original shape after deformation, it is desirable that in many cases the deformation needed for proper spatulation be performed at the heat-setting temperature of the material being used and that sufiicient cooling be subsequently employed while the deformed or spatulated fiber remains under spatulating compression to lock the stresses of spatulation in position.

As indicated above fibers spatulated in accordance with this invention must be compressible and capable of being permanently deformed at a temperature below their melting point. FIGS. 1 to 5 of the drawings illustrate different shaped thermoplastic filaments capable of spatulation. FIG. 1 shows a hollow filament which may be spatulated in accordance with this invention. When the filament of FIG. 1 is subjected to compressive force such that deformation or flattening of the fiber increases from one end of the filament to the other, it changes to the configuration illustrated in FIGS. 66d of the drawings.

Reference is made to FIGS. 2 to 5 which illustrate other embodiments of filaments which may be spatulated in accordance with this invention. FIG. 2 shows an alternate construction where two hollow striations run the length of the fibers. FIG. 3 shows a square hollow fiber and it is apparent that oval or other starting shapes may be used. FIG. 4 shows a cylindrical filament having longitudinal grooves which assist capillarity. FIG. 5 shows and X-shaped filament which obviously already has grooves which are most effective from a capillarity standpoint. When the X-shaped filament of FIG. 5 is subjected to compressive force such that deformation of the fiber increases from one end of the filament to the other, it changes to the configuration shown in FIG. 7. Ohviously instead of X-shaped filaments, filaments of other deformable shapes may be used such as those having X, H, etc. structural cross-sections.

In general, the diameter of the starting cylindrical filament of the type shown in FIG. 1 is in the range of 0.005 to 0.200" and the wall thickness is generally in the range of 0.001 to 0.050" depending upon the rigidity desired in the formed fiber. The filaments shown in FIGS. 2 to 5 would have the same general maximum and minimum dimensions as indicated for the shape of the filament of FIG. 1.

In the case of tubular vinyl chloride-acetate filaments as shown in FIG. 1 and for the other shapes described, the filaments are heated to 212 F. and cooled to F. under the spatulating force at which temperature the stresses of spatulation are locked in place. Further cooling gives additional insurance that the stresses are properly locked.

In the case of tubular filament made using a polymer based upon the condensation of hexamethylene diamine and sebacic acid, spatulation may be performed at 300 F. and since, in nylon of this type, the spatulated shape is permanent at any temperature below 300 F. or the spatulating temperature, only a small amount of cooling is required to set the spatulating deformation.

As the cross-section of the formed spatulated filament of FIG. 6 goes from circular at 6b to spatulate at 6d, stiffness and thickness of the filament as measured between spatulated surfaces decreases as shown in the graphs of FIGS. 8 and 9. Spatulation of the X-shaped fiber of FIG. 7 gives stiffness and thickness correlations in graphs of FIGS. 10 and 11. It is apparent that decreasing stiffness in the direction of the working end of spatulated hollow circular fibers as shown in FIG. 6 and spatulated X-shaped fibers as shown in FIG. 7 can, through proper design, be made to simulate in the direction of sweeping the stiffness characteristics of corn broom fiberthe diameter and stifiness correlations of which are shown in the graphs of FIGS. 12 and 13. l

The flattened spatulate working ends of fibers as shown in FIG. 6 and FIG. 7 flag much more readily than does a solid circular shape and the forces applied to such spatulated product during usage are such that flagging con- 1 tinues as the brush wears.

It is apparent from FIG. 14 that the spatulated end It) I of a fiber, formed in accordance with this invention, cov-. ers a much larger sweeping area in the direction of sweeping, 11, than would the small tip, 12, of a filament having 1 reducing diameter in the direction of the working end as shown in FIG. 15. The spatulated fiber is therefore a more effective sweeping medium.

Thus, the novel spatulated synthetic thermoplastic brush fibers have been shown to possess all of the elements of an ideal brush fiber previously listed.

Torealize the full potential of spatulated vfibers as I described, it is essential that the family of fibers at their non-working ends be mounted in a support, e.g.. brush engagemcnt withspacer members 33 and 34* and atatheir Removably secured to angularmembers 31, 31 aresupporting pins 7 free ends abut angular members ,31, 31.

. 36,66: which are slidably received in and extend through block, so that the longer dimension of the spatulate ends ofall the fibers be aligned .at right angles to the direction of sweepingin the same manner that the spatulate end of a single fiber, it is shown aligned at right angles to the direction of sweeping, 11, in FIG. 14.

This can be readily done with a brush that has been manufactured by conventional methods previously describedusing fibers capable of spatulation as the filling material. Insertion of a' family of un-spatulated fibersprotruding from'abrush' block into a mold as shown in 1 FIG. 16" followed by a heat-setting cycle adjusted temperature-wise for the thermoplastic being used results in a product in which the spatulate ends are aligned with their major dimension at right angles to the direction ofsweeping ,or painting.

As shown in FIGS. 16 to 18, the upper part, 21, of the mold, 2,. is guided into the lower .part, 22, of the mold by means of guide'pins, 23, after the unspatulated family of fibers of an already formed brush (not shown) has been placed in the cavity, 24. As shown in FIGURETIT the mold is provided with an end plate 29'. As the mold I closes to apply a pressureP before, during, or after heating the fiber to its suitable forming temperature, the angled 1 surfaces, 25, on the upper part, 21, of the mold, and. the

lower part, v22, of the mold, compress the fibers and re-' sult'in overallspatulation of the family of fibers in the direction ofthe working end of the brush.

The above explanation relates to spatulating the filaments of analready'forrned brush... A pre-determined Y quantity of individual fibers capable of spatulation which are not connected to a blllShblOCk can be processed similarly as in FIG. 18. In this case unconnected un-spatulated fiber ends 26 extend from the closed mold at 26.

These extended ends may. be heat-welded or cemented I as at 27 in FIG. 19 to give a brush-like productin :which the spatulated tips, 28, are aligned with their major :di-

mensions at right-angles to the direction of sweeping 29. As indicated heretofore,in :the case of a polymer made from hexamethylene diamine and sebacic acid, the heatsealing temperature used on the protruding ends. would be inthe order of 450 to 600- F. In the case of vinyl chloride-acetate, the welding temperature would be in the order of 275 to 400 F. V

In a numberof instances, it is desirable to make brooms with shapeas shown in FIG. 20. This can be accomplished by spatulating the non-working ends in the opposite direction from the spatulation imparted to the working ends.

This effect may be obtained by placing a pre-deter-.

spacer members- 33 and 34. Rotation of stud members 35, in appropriate directions cause forces to be applied 7 to angularme mbers 31,}31"v in directions indicated-byF and'F; This causes. movement of angular members 31 and 31 (and their attachments 32,3325) towards; each The aforedescribed movementof the opposing angular members 31, 31iand attachments 32, 32'] toward other.

each'other enables the angular membersSl, 31' and attachments 32, SZ'to press against; the contained fiber to eifect spatulation thereof. effected. before, during, or vafterpheating the. contained fiber to its heat setting temperature. 24, the angular men1bers'31, 31' andattachments'SZ', 32 spatulate the fiber in cavity 30 below line The height-of C.C depends on the quantity of fiber charged into the cavity and thesangle of membersl, 31' and 32, 32. members 313E315 'tendsrto flare out'as shown'iu FIG. 24.

Side-plate; member 37 is placed on pins 38 011 member 3% in FIG. 21 by meansofholes 40 in plate 37. Integral with plate; member-"3'7 'isiawedge memberfil having an,

inclined surface; 41a, A member 37f similar-to 37 is placed .on pinszcorrespo'nding to 38 ion theoppositeside;

of the assembly, on plate 39.. When, pressure 42 is applied tov the member :37 shown in FIG. 22 and to the corresponding part on pins on member 37', spatulation' of the fibers in the cavity above .C%Cis effected on the working ends of the fibers by surfaces 41a in a direction opposite to the .spatulation applied by'members 31, 31' and 32, .32 below line 'C Ci Removal ofplate 37'from part-359 and a, corresponding plate 37i from part-39f+ and the two parts 32,32 :from parts. 31, 31in FIG.724 by removal of fastenerbolts 32a leaves fiber extending below surface 43 of FIG. :21 and as shown in'FIG. 25.' This fiber extension may be heatwelded or cemented as shown at- 27 'inzFIG. 19. The same choice of temperature cycles exists for this doublespatulation as for the single spatulation describedin connection with the mold shown iIIFIGdl; r

Perfectly spatulated fibers iof the double. spatulation type would have varyin'g'cross-sectionsas shown inFIGS. 1 26'a26c. However, whena family of fibers is spatulated, I

interference from adjacent fibers prevents; perfect spatu-v lation. Analysis of actualconfigurations for. the sectionlocations shown in. FIGL26 are depicted 'in' FIG." 27; The analysis was based upon a brush double -spatulated in the mold shown in'FIGS; 21 to 24. v

It should be realized that the analysisshown in i 27 is merely for the purpose of illustrating the dilferent sectional config'urations'that were, obtainedffor a given: set of conditions; Spatnlationis a function of spatulating pressure so that variousdegrees of spatulation other than.

those shown are obtainable .and controllable.

v Spatulation of a ,brush made by'conve'ntional methods,

andsingle or-double spatulation of a family ofindividual fibers followed-by heatsealing :or cementing of the nonworking ends of same; to maintain the desired alignment of these fibers has bee'n described.

Heat-sealing or welding is jpreferable -to cementing.

It:follows then'thatwelding'or heat-sealing is an integral part of the-manufacture .of certain' spatulated brushes.

This recognition has made? apparent a new concept for the manufacturer of brushes which goes, hand .in hand with the concept of spatulated brushes, 5

This concept consists of: melting the non-working ends of fibers capable vof 'spatulation by contactain a heated cavity whose shape correspondsto the shape of a'brush block while at the same time molding'meansin the block for subsequently attaching a handle to the moldedblock.

'If the; necessary brush handle-was sufiiciently small, it

could be made an integral part ofthe: molded block.

The advantages of this methodof: making brushesis This movement may be As shown in FIG;

Fiber above C-C which'is' not compressed .by'

easaea t apparent when one considers the conventional methods presently used for brush manufacture.

.metal ferrule, curing the cement, and afiixing a handle to the opposite end of the ferrule from that in which the fibers are inserted.

Staple set brushes are made by pre-drilling holes in a plastic or wooden block, inserting fiber tufts bent in U shape into these holes and retaining the tufts with anchors or staples. In some instances the tufts are set with pitch rather than with staples. In other instances, the U shaped tufts may be retained by a wire which retains the tufts and runs from hole to hole.

Other brushes have been made by injection molding the block and coarse fibers simultaneously; injecting hot thermoplastic in the form of a stream around a group of fibers; retaining fibers in U-shape in a U-shaped metal strip with a wire, and by twisting two wires together with fiber between them.

Individual tufts have been heat-sealed at one end and used to fill single holes in staple-set brushes which the machine missed. There is no known instance where the melted non-working ends of brush fibers have been used to'form a-finished commercial brush block having means therein for subsequently attaching a handle to the molded block. Nor is it known to form a brush block in the manner described above wherein the handle is made an integral part of the molded block.

Certain thermoplastic brush fibers such as those made from hexamethylene diamine sebacic acid polymers, polycaprolactam and others are of such fluid nature when melted that gravity flow is sufficiently great to fill a cavity having the shape of a brush block if the cavity is heated above the melting point of the thermoplastic fiber being melted. Thus when a family of spatulate or non-spatullated thermoplastic fibers of the type described is permitted to melt and settle into a heated cavity having a shape corresponding to a desired brush block, and providing either meansfor attaching a handle to the molded brush, or, providinga handle as an integral part of the brush, melting of the fibers occurs, the cavity fills with melted polymer, and the resultant cooled product consists of a block made from melted fibers to which the unmelted fibers are welded in upright position.

Such an operation is demonstrated in FIGS. 28 and 28a. These figures illustrate the production of a brush construction wherein there is formed an integral handle on the brush block. Spatulated fibers are retained with their Working tips in essentially parallel arrangement in retainer 50. As retainer 50 is lowered into cavity 51 in mold 52 which. is heated by elements 53 to a temperature above the melting point of the fibers in 50, the fibers melt and form a handle 54 and block 55 to which the fibers in container 50 are welded. FIG. 28b illustrates the appearance of the brush upon removal from the cavity after cooling below the melting point of' the material which constitutes the fiber and the melted fiber block.

It is believed that this manner of fabricating brushes has not been commercially developed in the past because many thermoplastics are discolored and degraded when exposed to air for a brief time at the melting temperature. Black or dark-colored brushes so fabricated may not be too unEightly but degradation of the polymer would remam.

It has been established that performance of the function shown in FIGS. 28 and 28a in an inert atmosphere such as'nitrogen, carbon dioxide, or vacuum results in ;a product whose properties are not degraded. When melting is conducted in a vacuum, there is the added adfiber level, 63.

id vantage that the presence of voids in the melted block is minimized.

It is further believed that the manufacture of a brush in an inert atmosphere permits considerations that were not heretofore practical and applies to existing synthetic fibers as well as the new spatulate form.

For instance, in FIG. 29' the mold cavity 60 is provided with a removable screw 61, protruding into it. When melted fiber is molded around the screw and the screw is removed after cooling, a female thread is left in the molded block to which a handle with a corresponding male thread canbe afiixed. Where the fiber being melted is sufiiciently compressed as would be the case with fiber spatulated in the mold shown in FIG. 24, the heated screw 61 could be screwed through mold 60 and cut its own thread into the compressed fiber to a point 62 higher than the melted polymer level 63 and would leave a longer thread after cooling and removal of the screw than would result by just covering the thread to the melted A brush construction 65 as shown in FIG. 31 is formed by screwing the threaded portion 64a of handle 64 of FIG. 30 into the complementary threaded portion of the brush construction of FIG. 29.

Similarly, following the described techniques, a block could be formed as in FIG. 32 with a tapered hole 66, into which the projection 67 on the handle 68 of FIG. 33 could be force fitted to give a finished brush. The handle could if desired be made to fit sideways or in any other direct-ion.

Similarly, dissimilar fibers chemically could be spatulated together but it would be preferable that these dissimilar fibers be compatible.

In the manufacture of certain brushes, it is desirable to impart a tent effect to the arranged brush fibers. Such a product may be formed following the techniques previously described in a mold consisting of three parts as shown in FIG. 34. The fibers 70 are retained at the desired angle between parts 71 and 73 and parts 72 and 73. The fiber '70 may be either spatulated or nonspatulated. When the protruding ends of 70 are heat melted in a cavity as previously described a brush structure simulating a tent effect is obtained as shown by the brush construction 74 of PEG. 35.

In FIG. 36 parallel rows of spatulated or non-spatulated fiber are retained by parallel segments $6 of a retaining mold. Fusion of the fiber extensions 81 in a heated cavity as described results in a brush structure 82 as shown in FIG. 3'7.

It is apparent that structures other than those shown could be devised.

A further advantage of the melt process for making a brush lies in the fact that the block with attaching device 96 as shown in FIG. 38 can be made of extremely thin plastic @1 with minimum thickness webs 92 incorporated in the case structure to provide necessary block stiffness. Use of parallel rows of fiber 93 in such a brush as made in the mold depicted in FIG. 36 results in successive continuous rows of fiber which are a more effective sweeping medium than staggered rows of holes filled with fiber.

In certain instances, it may be desirable to introduce melted polymer into the block cavity to supplement that part provided by melted filament. The advantage would be that such supplementary melted polymer would cost less than an equivalent weight of melted brush fiber. Such supplementary melted polymer could be added to the cavityas granules which would melt in contact with the heated cavity or as a stream of molten polymer. In either case, part of the block would necessarily consist of melted fiber to secure necessary welding. The supplementary polymer described may not be the same material as the melted brush fiber but it would preferably be one that is compatible with the polymer of which the melted fiber consists. I

Inthe apparatus described hereinbeforefor spatulating p ases;

1 l filaments, conventional solid filaments, e;-g. circular solid filaments may be spatulated individually using-the:thermo plastics noted but in a family of solid circularfibers, with the apparatus used for spatulatingnthe various embodiments described hereinbefore, spatulation is ineffective,

The

band of filaments 165i), pulled between rolls 101 and102 H by force A, are spatulated over part of their length between surfaces 164 and N5 of rolls 1M and 192, respectively, which are rotated such that these surfaces move in the direction of the band of filaments 100. Asthe radial distance between the eccentric axisliiS andsurfacej105:

changes. I) to a as roll iti2'rotates, the degree of spatulation decreases. As the radial distance increases again from a to b, the degree of spatulation increases.

It is obvious that solid filaments of any cross-section maybe spatulated in accordancewith the above-described technique. It is also clear that various modifications may be-employed to efifect the. desired spatulation. For

example, in place of the eccentric'ally mounted roll 102 one may use a roll of a trefoil shape.

In summary, it has-been shown ,that'spatulated synthetic brush fibers more .closely approach the desirable prop fix the spatulatedends improper relationship; that the melted non-working ends ,may form a ,multiplicityjof shapes which would act as. the finished brushblo'ck; and that by conducting the melting of the non-working ends in a cavity in an inert atmosphere degradation of the color and physical'properties of theymelted non-working ends is avoided.

It has been shown that the physical prope1ties::-of heat-setting temperatures, melting characteristics, and

structural strength of the melted brush fibers have become for thefirst time considerations that should be weighed in the manufacture of a brush. i

The invention in its broader aspects is not Iimited to ."W the specific steps, methods, compositions, combinations and improvements described but departures may be made therefrom within the scope of the accompanymgclauns without departing from the principles of theinvention and without sacrificing its chief advantages.

What is claimed is:

1. A method for making a spatulated brushtfrom a family of synthetic compressible fibers in essentially paral-' le'l arrangement comprising: applying a deformingvcoma pressive forcefupon said family of fibers so asto eifect deformation of said fibers along their longitudinalaxiswith respect to the cross-sectional profile of-the fibers priorto' application of the compressive force, the extent to which 7 said compressive force deforms each of, the fibers increasing from -a comparatively small extent at a first point along, the longitudinal axis of the fiber to a comparatively large extent at a second point along .its longitudinal axis,

such increase in deformation between said first and second point resulting in an increasingly spatulated portion be:

along the length of the fiber, a progressive decrease. in 7 thickness, a corresponding increase in width, and a cor-g responding decrease in stiffness of the fiber=in the direction of the applied compressive force,

2,. A; method for making-a spatulated brush according to claim '1 wherein the deforming .compressive ,forceyis' applied to the fibers such that the fibers-are vincreasingly spatulated in:the direction of one common end; aIld.S-.'

curing together the, non-working, ends in such a manner to :rnaintain general para-llelalignment. offthe spatulated working ends.

3. A method formaking a spatulated brush'according 2 to claim lwherein thedeforming compressive force is;

applied to fibers protruding fromth-e brush'blockfof-a brush such that the fibers are increasingly spatulated in a the direction of their working ends and such'jthat the spatulated working ends are in general parallel, alignment.

4. A method for making a spatulated brush-according to claim 1 wherein thedeforming compressive forceis applied to the fibers such that the fibers are increasingly spatulated in the direction of one common end, and such a predetermined shape.

5. A method for making, a spatulated brush according; to claim '1 wherein a'defor-ming compressive forceis appliedto the fibers so that part of thelength of fibers is increasingly-spatulated in'onewsptatulatingdirection andv I V wherein a second compressive force is applied to the fibers such that a second part of. the length of fibers is increasingly spatulated in a difierent direction than the first spatulated partyand supporting said fibers :at one common end tomaintain the angular relationship of the respective spatulated parts.

6; A method for making a spatulatedbrush according a to, claim 1 wherein a deforming compressive force is applied to the fiberssothatpart of the-length of fibers is increasinglyspatul-ated in the direction of one common end anduwherein a second compressive forceis applied i tov the fibers'such that another part of the length of thefibers at the other end is increasingly spatulated-in the directioniof the other common end and in-a spatulatingw direction turned from the spatul-ating rforceiapplied1' to the first end; and securing together the fibers at one: spatulated -end,to maintain the,90 relationship of the opposite" spatulated ends; a

7. The method .of claim 6 wherein at onezend are secured together by heat welding. 1 e

' 8. A method for making, a spat-ulatedbrush according} to claim 1 wherein ;the deforming comprcssiveior-ce-is" applied to fiber-s protruding: from the; brush block of; a

direction of application; heat-setting the fibers while they are under the compressive force; and cooling the heat-set, I spatulated fibers under compression to a point :where thev compressive stresses can no longer exert plastic memory and cause the spatulated fibers to return to their; original shape uponv removal of the compressive force,

9. A method for making a spatulatedbrush according;

to claim 1 wherein'the deforming compressive force is applied to the fibers: such that the, fib'ers'are increasing-ly spatulated in :the directionof one common end, andv such, that the spatulated ends have their major dimension in' general parallel arrangement; heat-setting the fibers while they are-under the compressive force; and cooling. the heat-set, spatulated fibers-to a point where the compressive, spatulating stresses can no longer exert plastic'mem- 1 oryand' cause 1 the :spatulated :fibe-rs to return to their original shape upon removal of-the compressive force;

and securing {togetherv the spatulated ends to form a brush of a predetermined shape.

10. A method for making a spatulated brush according to' claim .1 wherein there is appliedto the. fibersrtwo de- 1 forming compressive forces such that the fibers have one; part of their lengthincreasingly spatulated in one spatulat- I t ing direction, and a second part of their length increasingly spatulated in a different spatulating directionQhe-at- 1 the spatulated fibers setting the fibers while under the compressive forces; securing together said fibers at one common end to maintain the respective spatulations in proper angular relationship; and cooling the heat-set, spatul-ated fibers under compression to a point Where the compressive stresses can no longer exert plastic memory and cause the spatulated fibers to return to their original shape upon removal of the compressive force.

11. A method for making a spatulated brush according to claim 1 wherein there is applied to the fibers two deforming compressive forces such that the fibers have one part of their length increasingly spatulated in the direction of one end of the family of fibers, and the remaining part of the length increasingly spatulated in the direction of the other end of the family of fibers in a spatulating direction t-urn 90 from the spatulation of the first end; heat-setting the fibers while under the compressive forces; securing together the non-Working ends to maintain the 90 relationship of the opposite spatulated ends;

and cooling the heataset, spatulated fibers under compression to a point Where the compressive stresses can no longer exert plastic memory and cause the spatulated fibers to return to their original shape upon removal of the compressive forces.

References (liter! by the Examiner UNITED STATES PATENTS 2,433,325 12/1947 Slaughter 30021 X 2,517,707 8/1950 Payne 264-85 2,664,316 12/1953 Winslon et a1 300-21 2,803,054 8/1957 Kohring 264101 X 3,053,575 9/1962 Zei'lstra 3002l FOREIGN PATENTS 148,853 10/ 1952 Australia.

GRANVILLE Y. CUSTER, JR., Primary Examiner. 

1. A METHOD FOR MAKING A SPATULATED BRUSH FROM A FAMILY OF SYNTHETIC COMPRESSIBLE FIBERS IN ESSENTIALLY PARALLEL ARRANGEMENT COMPRISING: APPLYING A DEFORMING COMPRESSIVE FORCE UPON SAID FAMILY OF FIBERS SO AS TO EFFECT DEFORMATION OF SAID FIBERS ALONG THEIR LONGITUDINAL AXIS WITH RESPECT TO THE CROSS-SECTIONAL PROFILE OF THE FIBERS PRIOR TO APPLICATION OF THE COMPRESSIVE FORCE, THE EXTENT TO WHICH SAID COMPRESSIVE FORCE DEFORMS EACH OF THE FIBERS INCREASING FROM A COMPARATIVELY SMALL EXTENT AT A FIRST POINT ALONG THE LONGITUDINAL AXIS OF THE FIBER TO A COMPARATIVELY 